Method and apparatus for enhancing combustion in an internal combustion engine through use of a hydrogen generator

ABSTRACT

The present device a hydrogen generator includes a housing for an electrolytic core, wherein the housing containing electrolyte solution. The electrolytic core includes an inner cathode concentrically oriented inside an outer anode immersed in the electrolyte solution for electrolysis. Additionally a vertically oriented separation pipe concentrically surrounds the upper part of the anode such that there is an overlap portion between the anode and the separation pipe, wherein the separation pipe extending above an electrolyte level. There is also a device for applying electrical power to the anode and cathode to create electrolysis there between which releases hydrogen and oxygen gases.

This application claims priority from U.S. provisional application61/267,580 filed Dec. 8, 2009 by Robert Talarico under the title: METHODAND APPARATUS FOR ENCHANCING COMBUSTION IN AN INTERNAL COMBUSTION ENGINETHROUGH USE OF A HYDROGEN GENERATOR.

FIELD OF THE INVENTION

The present invention relates generally to internal combustion enginesand the use of electrolytic generated hydrogen and oxygen to enhancecombustion efficiencies and cleanliness and more particularly to anelectrolyser device designed for use in automobiles or other vehiclesthat produces the requisite amount of hydrogen and oxygen through anelectrolysis process.

SUMMARY OF THE INVENTION

The present invention employs a unique electrolyte cell, combinationanode and cathode and gas feed controls in an easily adaptableenvironment within the fuel system to produce hydrogen gas in anelectrolysis process on demand and to enhance combustion without theneed for storage tanks and the like in a safe and efficient manner.

The hydrogen generator includes: a housing for an electrolytic core, thehousing containing electrolyte solution, wherein the electrolytic coreincludes an inner cathode concentrically oriented inside an outer anodeimmersed in the electrolyte solution for electrolysis. It also includesa vertically oriented separation pipe concentrically surrounds the upperpart of the anode such that there is an overlap portion between theanode and the separation pipe, wherein the separation pipe extendingabove an electrolyte level a means for applying electrical power to theanode and cathode to create electrolysis there between which releaseshydrogen and oxygen gases.

Preferably wherein the anode and cathode are vertically orientedcylinders.

Preferably wherein the overlap portion between the anode and theseparation pipe being at least 10% of the overall length of the anode.

Preferably wherein the separation pipe further includes vent holeslocated just above the electrolyte level.

Preferably wherein the portion of the separation pipe above theelectrolyte level defining an upper portion of the housing forcollecting gases therein.

Preferably wherein the anode and cathode being of unequal lengths andpartially overlapping along an overlap length.

Preferably wherein the anode being shorter than the cathode such that acathode non overlap length is along the bottom of the cathode.

Preferably wherein the cathode non overlap length being at least 10% ofthe length of the cathode.

Preferably wherein the housing being a T shaped housing including asmaller lower portion defining a lower volume and a larger centralportion defining a central volume, wherein the smaller lower portionhouses electrolyte solution and the electrolytic core and centralportion houses electrolyte solution.

Preferably wherein the central volume is at least 50 percent larger thanthe lower volume.

Preferably wherein the central volume is at least 100 percent largerthan the lower volume.

Preferably wherein the housing being a cross shaped housing including asmaller lower portion defining a lower volume, a larger central portiondefining a central volume, and an upper portion defining an upper volumefor collecting gases, wherein the smaller lower portion houseselectrolyte solution and the electrolytic core, and the central portionhouses electrolyte solution.

Preferably wherein the portion of the separation pipe above theelectrolyte level defining the upper portion of the housing forcollecting gases.

Preferably wherein the exterior and interior surface of the anode iscoated with tantalum and the interior surface of the anode isadditionally coated with platinum.

Preferably wherein the cathode exterior and interior surface is coatedwith tantalum.

Preferably further including a heating element for heating theelectrolyte solution.

Preferably wherein the heating element extending centrally within theseparation pipe and the electrolytic core.

Preferably further including are circulating pump in fluid communicationwith the housing for circulating electrolyte solution through thehousing and through a cooling radiator for cooling the electrolytesolution.

Preferably wherein the power means including a power supply connected toa pulse width modulator connected in parallel to a large capacitor fordelivering power to the electrolytic core.

Preferably wherein the capacitor is at least 5 farads.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described by way of example only withreference to the following drawings in which:

FIG. 1 is a schematic cross-sectional view of the hydrogen generatortogether with the gas feed components.

FIG. 2 is a schematic cross-sectional view of the hydrogen generatorshowing schematically the flow of the off gas bubbles.

FIG. 3 is a schematic cross-sectional elevational view of the anode andcathode configuration.

FIG. 4 is a schematic top end plan view of the anode and cathode showingthe various coatings applied to the exterior surfaces.

FIG. 5 is a enlarged schematic cross-sectional view taken along lines5-5 of FIG. 3 showing the material compositions and coatings of theanode and cathode.

FIG. 6 is a partial schematic cross-sectional view of the upper portionof the hydrogen generator together with the gas feed components.

FIG. 7 is a schematic electrical wiring diagram of the electrical andelectronic components used in association with the hydrogen generator.

FIG. 8 is a schematic flow chart showing the steps for coating the anodetube.

FIG. 9 is a schematic flow chart showing an alternate method and stepsinvolved with coating the cathode.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present device and method for enhancing combustion in an internalcombustion engine through the use of a hydrogen generator is showngenerally as hydrogen generator 100 together with gas feed components103 in FIG. 1.

Referring to FIG. 1 the major components of hydrogen generator 100include electrolytic cell 101 and gas feed components 103. Depending onthe application some or all of the gas feed components 103 may beutilized.

Electrolytic cell 101 includes a housing 104 having a lower portion 118,a central portion 114 and an upper portion 110. Electrolytic core 102includes the anode 124, a cathode 128 which are connected electricallyat anode terminal 126 and cathode terminal 130. Anodes 124 and cathode128 are housed within lower portion 118 whereas separation pipe 112extends from the top of lower portion 118 all the way to the top ofupper portion 110. The portion of the separation pipe 112 above theelectrolyte level 134 defines the upper portion 110 of the housing 104for collecting gases therein.

Lower portion 118 defines a lower volume 120 which essentially is thevolume within the lower portion 118 of housing 104. Although notapparent from the drawings tower portion 118 is preferably cylindricalin shape and anode 124 and cathode 128 are preferably concentricallymounted cylinders. Lower portion 118 also includes a removable bottomcap 122 for mounting of the anode 124, cathode 128 as well as anodeterminal 126 and cathode terminal 130 therein.

Electrolytic cell 101 also preferably includes a heating element 502which enters upper portion 110 at a element entry 506 which is sealedoff with as seal 504. Heating element 502 extends downwardly and iscentrally located within separation pipe 112 and cathode 128 in order toheat the electrolyte when required. Heating element 502 is controlled bya thermistor or a thermocouple 142.

Housing 104 includes a housing jacket 169 which includes at lowerportion 118 a bottom cap 122 and core sides 175. Housing jacket 169further includes in the central portion 114 a bottom wall 171 and a topwall 172 and side walls 177. Housing jacket 169 farther includes in theupper portion 110, upper side walls 179 and top cap 160. In some caseshousing 104 may be made of cylinders with the central portion 114 beinga cylinder mounted in a horizontal position and the upper portion 110and lower portion 118 being cylinders mounted in vertical positions,wherein the cylinders are welded or otherwise connected together.

Separation pipe 112 extends and overlaps with anode 124 and cathode 128.In particular the bottom of separation pipe 112 extends below thecathode anode top 125 thereby creating an overlap portion 181 as shownin FIGS. 1 and 2. Preferably overlap portion 181 being at least 10% ofthe overall length of the anode.

Central portion 114 defines a central volume 116 which houses amongother electrolyte solution 132 shown in the diagrams and havingelectrolyte level 134. The space created between the top of electrolytelevel 134 and top wall 172 is shown as free space 135. Separation pipe112 has defined therein vent holes 148 which provide communicationbetween free space 135 and the interior of separation pipe 112.Electrolyte solution 132 is circulated through electrolytic cell 101 anddiverted through cooling pipes 136 and cooling radiator 138 withre-circulating pump 140.

Referring to FIG. 2 electrolyte solution 132 flows as shown by thearrows 166 in FIG. 2.

In addition to circulating electrolytic solution 132, re-circulatingpump 140 also passes the electrolyte solution 132 through a coolingradiator 138 shown schematically in FIGS. 1 and 2. In this manner thetemperature of electrolyte solution 132 can be controlled.

Hydrogen generator 100 also includes gas feed components 103 shown inFIG. 1 and also in FIG. 6. Gas line 150 is connected near the top ofupper portion 110 providing for communication of gases from the top ofseparation pipe 112 into gas line 150.

Off gas bubbles 170 shown in FIG. 2 are created through electrolysis inelectrolytic core 102. Off gas bubbles 170 include hydrogen gas as wellas oxygen gas as well as water vapour which percolates upwardly withinseparation pipe 112 until it reaches the upper portion 110 filling theupper volume 108 with the off gas bubbles 170. This gas then passesthrough gas line 150. The gases first pass through s vapour filter 508which sends any entrained water back into housing 104. Vapour filter 508can be a porous metal filter or other filter systems known in the artwhich dries the gas prior to proceeding through gas line 150. Flow ofgas through gas line 150 is controlled with a needle valve 152, a oneway valve 154 and eventually is communicated to the gas outlet 156 whichcommunicates with the intake portion of an internal combustion enginefor example. Some or all of these components may not be necessarydepending upon the operating set up.

Due to the high amount of vacuum created in internal combustion engineson the intake side of the motor, the amount of vacuum within gas line150 and ultimately within the upper volume 108 of upper portion 110 ofelectrolytic cell 101 may be quite significant. Therefore in order tocontrol the electrolysis process and to ensure it proceeds in a uniformand controlled manner a relief valve 146 is mounted onto the upperportion 110 of housing 104 communicating with the upper volume 108 ofupper portion 110 thereby allowing air to enter into the upper volume108 should the vacuum within upper volume 108 exceed a pre-determinedvalue. The negative pressure 168 in the upper volume 108 of upperportion 110 aids the evolution and the movement of off gas bubbles 170from the lower portion 118 through the central portion 114 andultimately through to the top of upper portion 110.

In regard to housing 104, the reader will note that the lower portion118 of housing 104 has a lower width LW 164 defined by core sides 175.The central portion 114 of housing 104 has a central width CW 162defined by side walls 177 and the upper portion 110 has an upper widthUW 160 defined by the upper side walls 179 of housing jacket 169.

Anode and Cathode Configuration

Referring now to FIGS. 3, 4 and 5 which show the arrangement to thecathode relative the anode and the coatings that are used for both thecathode and anode.

Referring to FIG. 3 which is a schematic cross-sectional view of theentire length of the anode and cathode, the reader will note that theanode 124 and cathode 128 are two concentric cylinders mounted onewithin the other and spaced apart with non-conductive spacers 172. Thecathode 128 is somewhat longer and extends significantly lower than theanode 124. FIG. 3 schematically depicts the overlap length 191 which isthe length along which the anode 124 and the cathode 128 are positionedin overlap fashion. FIG. 3 also depicts the cathode non overlap length193 which is the bottom 520 most portion of the cathode 128 which is notmounted in overlap orientation with respect to the anode 124. Thecathode non overlap length 193 aids in the circulation of theelectrolyte solution 132 through the gap 195 which is the space definedbetween the anode 124 and the cathode 128. Preferably the cathode nonoverlap length 193 being at least 10% of the length of the cathode.

Referring now to FIGS. 4 and 5, the materials used for the anode 124 andthe cathode 128 are depicted including the coatings that are appliedupon the surfaces of the anode 124 and cathode 128.

The core of both the anode 124 and cathode 128 is preferably stainlesssteel 180 and 188, however it could be other materials known in the artto be efficient in working as an anode 124 and cathode 128.

Referring first of all to cathode 128 which is the inner most concentriccylinder, stainless steel core 188 is coated with tantalum 190 on theinterior and also coated with tantalum 190 on the exterior of cathode128. Therefore, cathode 128 is completely coated with tantalum on boththe interior and exterior surfaces. In some cases it is not necessary tocoat the cathode 128.

Referring now to anode 124 which is preferably comprised of a stainlesssteel core 180 is coated on the exterior surface with tantalum 182, andon the interior surface with tantalum 184 and then further coated withplatinum 186 on the interior surface of anode 124.

Therefore, anode 124 ultimately has an exterior surface coating oftantalum 182 and an interior surface coating of platinum 186.

FIG. 8 shows schematically the steps and the method used to coat theanode for example. A stainless steel cylindrical anode 302 is used.Chemical vapour deposition techniques are used to deposit a coating oftantalum onto all exterior and interior surfaces of anode tube step 304.

Step 305 plating platinum onto the interior surface of anode 124 bychemical or physical vapour deposition or electroplating or any otherprocess known in the art which may be suitable.

Therefore in the process schematically shown in flow chart form FIG. 8,anode 124 is first coated with tantalum on both sides using vapourdeposition and then is coated with platinum on only the interior surfaceby either chemical vapour deposition and/or by using an electroplatingprocess. Persons skilled in the art will know that other platingprocesses such as electroplating or other means may also be used.

FIG. 9 shows in flow chart schematic fashion the method for coating thecathode 128. Preferably the cathode 128 is made of stainless steeltubing which is a stainless steel cylindrical tube which is then subjectto the chemical vapour deposition of tantalum onto both the exterior andinterior surfaces of the tube resulting in a cathode 128 which is coatedon all surfaces with a chemical vapour deposited layer of tantalum.

Electrical Wiring

Referring now to FIG. 7 the electrical wiring is shown schematically inFIG. 7 as electrical wiring 200.

Electrical wiring 200 includes a battery 218 which is normally anautomotive battery and/or the vehicle battery which is grounded on oneend 220 and power is applied through a circuit breaker 216 and a relay214 thereby powering the electrical wiring circuit 200 as shown in FIG.7. Power is applied to radiator fan motors 202 shown as F in FIG. 7,re-circulating pump motors 204 shown as M in FIG. 7, a timer relay shownas 206 together with a thermistor or thermocouple 142 which is mountedin the electrolytic core 102.

Power is further applied to a large capacity capacitor 208 which isgrounded at 210 and finally power is applied to the cathode terminal 130and the anode terminal 126 through the pulse width modulator 137 asshown in the electrical wiring diagram, which in turn applies power tothe cathode 128 and anode 124. Capacitor 208 is at least 5 farads insize.

In addition a heating element 502 is controlled with a thermocouple 142and a relay 206.

In Use

The electrolytic core 102 is comprised of two cylindrical metal tubesnamely the anode 124 and the cathode 128. The placement of the tubes isconcentric and are held in place with a non-conductive heat and chemicalresistant spacers 172. The inner tube preferably being the cathode 128is longer than the outside tube preferably being the anode 124 at thebottom while they are flush at the cathode anode top 125. The differencein length creates a cathode non overlap length 193 and a overlap length191 where both the cathode and the anode are in overlap fashion.Preferably the non overlap length 193 is at least five percent (5%) ofthe overlap length 191, and preferably at least 10% of the over laplength 191. This configuration helps the electrolyte solution 132 toflow more easily into gap 195 which is the space between the cathode 128and the anode 124. The inventors have found that hydrogen production canbe significantly increased by providing for the cathode non overlaplength 193 as depicted in FIG. 3 of the drawings, as it will guide andassist the water flow in between the anode and the cathode to flow inmore easily.

Both the anode 124 and optionally the cathode 128 are coated entirelywith tantalum to avoid oxidation. The tantalum coating shown as 182, 184and 190 in FIG. 5 is normally a few microns in thickness, usually about50 microns however it could be somewhat less or somewhat more dependingupon the life expectancy required from the cathode 128 and the anode124. In order to have proper galvanic conductivity through theelectrolyte between the electrodes, another conductive metallic layerusually is necessary. In this case a further coating of the interiorsurface of the anode 124 with the platinum 186 is preferable to aid theconduction process. Normally the bulk of the electrolysis takes placebetween the inside surface of the anode and the outside surface of thecathode and coating the whole surface of the anode with platinum forexample is both unnecessary and costly. In practice it has been found inorder to optimize the production of hydrogen and oxygen and to maximizethe life of both the cathode and the anode, it is not necessary to applythe platinum metallic layer to either the interior surface or theexterior surface of the cathode.

Electrolytic cell 100 has a cross shaped housing 104 which contains aseparation pipe 112 which is oriented vertically and overlaps somewhatwith the anode 124 and cathode 128 at the overlap portion 181. Notdepicted housing 104 may also be T shaped wherein the upper portion 110and central portion 114 are of similar dimensions. Preferably howevercentral volume 116 is significantly greater than lower volume 120 andpreferably central volume 116 is 50% larger than lower volume 120 andmore preferably is 100% larger than lower volume 120. The separationpipe encircles and overlaps the cathode and anode top 125 along theoverlap portion 181 and extends to the top of the upper portion 110 ofhousing 104. Separation pipe 112 includes vent holes 148 to allow forthe flow of gases including hydrogen and oxygen gas which is trapped inthe free space 135 of the central portion 114 of housing 104. Due to thecross shaped housing 104, the central volume 116 is significantly largerthan the lower volume 120 and provides a large reservoir of electrolytesolution 132 to be housed within central volume 116. Therefore,replenishment of electrolytic solution 132 is minimized.

Secondly, circulation of the electrolyte solution 132 through coolingpipe 136, cooling radiator 138 and re-circulating pump 140 is aided bygravity as depicted in FIG. 2. The inlet of the solution is near theupper portion of central portion 114 and the outlet is on the bottomwall 171 of central portion 114. The use of separation pipe 112 channelsthe evolution of off gas bubbles 170 and helps the flow of electrolytesolution 132 into the lower portion 118 as shown by the arrows 166 inFIG. 2. Rising off gas bubbles 170 will tend to move electrolytesolution 132 upwardly within separation pipe 112 thereby encouragingflow of electrolyte solution 132 downwardly outside of separation pipe112 as depicted by flow arrow 139. In addition, the use of separationpipe 112 which projects substantially above the electrolyte level 134ensures that electrolyte solution 132 is not pulled through gas line 150should there be a strong vacuum or negative pressure 168 in the uppervolume 108. In addition, relief valve 146 is included in case of an overnegative pressure 168 condition.

The electrolyte is preferably comprised of distilled water and potassiumhydroxide and optionally a small amount of denatured alcohol. Otherelectrolytes may also be suitable such as calcium chloride and smallamounts of ethylene carbonate may also be used. Potassium hydroxide actsas a catalyst to induce the electrolytic process and the denaturedalcohol is to prevent freezing. If applied in the right concentration ofapproximately 25% or more by weight, the electrolytic solution won'tfreeze up to temperatures of −40° Celsius. Alternately the heatingelement 502 can be used to prevent freezing. Optionally also a smallamount of methylene carbonate is added to the solution for its chemicaland thermal stabilizing properties. This electrolyte under normalconditions may not need to be replenished in the system since typicallyit does not degenerate or is used up by the electrolyses process.Usually only water needs to be added from time to time to theelectrolytic cell 101.

Capacitor 208 shown in FIG. 7 of the electrical wiring diagram 200 has avery high farad value of approximately 1.5 to 9 farads preferably 6farads to be able to ensure that the power obtained from an automobiles12 volt battery and alternator are continuous enough to ensure thathydrogen production can be maintained even during low production periodsof electricity from the alternator. Use of the high farad capacitor 208creates a higher sustained input of power into electrolytic cell 101without large power fluctuations effecting the operation of the hydrogengeneration. The adjustable needle valve 152 regulates the amount ofhydrogen gas that enters the cars intake manifold at the gas outlet 156.One way pressure valve 154 allows the hydrogen gas to flow one way intothe engine through the throttle body or air intake manifold and preventshydrogen gas to flow backwards which would decrease efficiency andprevent sparks to enter back into the system.

The adjustable relief valve 146 relieves negative or dead vacuumpressure which increases the flow of hydrogen through gas line 150 togas outlet 156 and into the engine intake. Relief valve 146 preventsnegative vacuum pressure to reduce or stop the delivery of hydrogenthrough gas line 150 and out through gas outlet 156 and into the engineintake manifold. The vacuum help pulls gas from the upper volume 108 ofhydrogen generator 100 and in addition relief valve 146 allows a weakflow of air to pass in from the outside into upper volume 108. Thisadjustable leak created by relief valve 146 prevents the full force ofthe vacuum from acting in the upper volume 108, which could stop orseverely decrease the delivery of the hydrogen gas to the engine.

It should be apparent to persons skilled in the arts that variousmodifications and adaptation of this structure described above arepossible without departure from the spirit of the invention the scope ofwhich defined in the appended claim.

1) A hydrogen generator comprising: a) a housing for an electrolyticcore, the housing containing electrolyte solution, b) the electrolyticcore includes an inner cathode concentrically oriented inside an outeranode immersed in the electrolyte solution for electrolysis, c) avertically oriented separation pipe concentrically surrounds the upperpart of the anode such that there is an overlap portion between theanode and the separation pipe, wherein the separation pipe extendingabove an electrolyte level, d) a means for applying electrical power tothe anode and cathode to create electrolysis there between whichreleases hydrogen and oxygen gases. 2) The hydrogen generator claimed inclaim 1 wherein the anode and cathode are vertically oriented cylinders.3) The hydrogen generator claimed in claim 1 wherein the overlap portionbetween the anode and the separation pipe being at least 10% of theoverall length of the anode. 4) The hydrogen generator claimed in claim1 wherein the separation pipe further includes vent holes located justabove the electrolyte level. 5) The hydrogen generator claimed in claim1 wherein the portion of the separation pipe above the electrolyte leveldefining an upper portion of the housing for collecting gases therein.6) The hydrogen generator claimed in claim 1 wherein the anode andcathode being of unequal lengths and partially overlapping along anoverlap length. 7) The hydrogen generator claimed in claim 1 wherein theanode being shorter than the cathode such that a cathode non overlaplength is along the bottom of the cathode. 8) The hydrogen generatorclaimed in claim 7 wherein the cathode non overlap length being at least10% of the length of the cathode. 9) The hydrogen generator claimed inclaim 1 wherein the housing being a T shaped housing including a smallerlower portion defining a lower volume and a larger central portiondefining a central volume, wherein the smaller lower portion houseselectrolyte solution and the electrolytic core and central portionhouses electrolyte solution. 10) The hydrogen generator claimed in claim9 wherein the central volume is at least 50 percent larger than thelower volume. 11) The hydrogen generator claimed in claim 9 wherein thecentral volume is at least 100 percent larger than the lower volume. 12)The hydrogen generator claimed in claim 1 wherein the housing being across shaped housing including a smaller lower portion defining a lowervolume, a larger central portion defining a central volume, and an upperportion defining an upper volume for collecting gases, wherein thesmaller lower portion houses electrolyte solution and the electrolyticcore, and the central portion houses electrolyte solution. 13) Thehydrogen generator claimed in claim 12 wherein the portion of theseparation pipe above the electrolyte level defining the upper portionof the housing for collecting gases. 14) The hydrogen generator claimedin claim 1 wherein the exterior and interior surface of the anode iscoated with tantalum and the interior surface of the anode isadditionally coated with platinum. 15) The hydrogen generator claimed inclaim 14 wherein the cathode exterior and interior surface is coatedwith tantalum. 16) The hydrogen generator claimed in claim 2 furtherincluding a heating element for heating the electrolyte solution. 17)The hydrogen generator claimed in claim 16 wherein the heating elementextending centrally within the separation pipe and the electrolyticcore. 18) The hydrogen generator claimed in claim 1 further includingare circulating pump in fluid communication with the housing forcirculating electrolyte solution through the housing and through acooling radiator for cooling the electrolyte solution. 19) The hydrogengenerator claimed in claim 1 wherein the power means including a powersupply connected to a pulse width modulator connected in parallel to alarge capacitor for delivering power to the electrolytic core. 20) Thehydrogen generator claimed in claim 1 wherein the capacitor is at least5 farads.